Modular Magnetic Encoders

Transcription

1 Modular Magnetic Encoders September 2012

2 The ERM modular encoders from HEIDENHAIN consist of a magnetized scale drum and a scanning unit with magnetoresistive sensor. Their MAGNODUR measuring standard and the magnetoresistive scanning principle make them particularly tolerant to contamination. Typical applications, usually with reduced accuracy requirements, include machines and equipment with large hollow shaft diameters in environments with large amounts of airborne particles and liquids, for example on the spindles of lathes or milling machines. Information on Angle encoders without integral bearing Angle encoders with optimized scanning Angle encoders with integral bearing Rotary encoders Encoders for servo drives Linear encoders for numerically controlled machine tools Exposed linear encoders HEIDENHAIN interface electronics HEIDENHAIN controls is available on request as well as on the Internet at This catalog supersedes all previous editions, which thereby become invalid. The basis for ordering from HEIDENHAIN is always the catalog edition valid when the contract is made. Standards (ISO, EN, etc.) apply only where explicitly stated in the catalog. 2

3 Contents Overview Selection guide 4 Applications 6 Technical characteristics Properties 8 Measuring principle Measuring standard Magnetic scanning Incremental measuring method 9 Measuring accuracy 10 Mechanical design types and mounting 12 General mechanical information 15 Specifications Modular encoder Series Signal period (at circumference) With incremental interface ERM 2200 Approx. 200 µm 16 ERM 200 Approx. 400 µm 18 With purely serial EnDat interface For very high speeds, with incremental interface ERM 2410 Approx. 400 µm 20 ERM 2400 Approx. 400 µm 22 ERM 2900 Approx µm 24 Electrical connection Interfaces Incremental signals» 1 V PP 26 «TTL 28 EnDat 30 Cables and connecting elements 32 General electrical specifications 34 HEIDENHAIN measuring equipment and accessories 38

4 Selection guide Overall dimensions in mm Diameter Line count Signal period ERM 2200 series D1: 70 mm to 380 mm D2: mm to mm to Approx. 200 µm ERM 200 series D1: 40 mm to 410 mm D2: mm to mm 600 to Approx. 400 µm ERM 2410 series D1: 40 mm to 410 mm D2: mm to mm 600 to Approx. 400 µm ERM 2400 series D1: 40 mm to 100 mm D2: mm to mm D1: 40 mm; 55 mm D2: mm; mm 512 to Approx. 400 µm 512; 600 ERM 2900 series D1: 40 mm to 100 mm D2: mm to mm 192 to 400 Approx µm 1) The position value is generated internally from the incremental signals after traverse over two reference marks. 4

5 Mechanically permissible speed Mounting the scale drum Interface Model Page min 1 Fastening by axial screws» 1 V PP ERM to 3000 min min 1 Fastening by axial screws «TTL ERM to 3000 min 1» 1 V PP ERM 280 ERM 2200 ERM min 1 Fastening by axial screws EnDat 2.2/22 1) to 3000 min 1 ERM ERM min 1 to min 1 Friction-locked fastening by clamping the drum» 1 V PP ERM min 1 ; Friction-locked fastening by min 1 clamping the drum; additional slot for feather key as anti-rotation element» 1 V PP ERM 2485 ERM min 1 to min 1 Friction-locked fastening by clamping the drum» 1 V PP ERM ERM

6 Applications Requirements on productivity and machining quality are steadily increasing. The complexity of workpieces and changing operating conditions due to small batch sizes in part manufacturing are likewise increasing. This must be considered in a production machine s conception and mechanical design in order for such machines to work highly efficiently and precisely. The robust ERM modular magnetic encoders are especially suited for use in production machines. Their large inside diameters offered, their small dimensions and the compact design of the scanning head predestine them for the C axis of lathes, rotary and tilting axes (e.g. for speed measurement on direct drives or for integration in gear stages), and spindle orientation on milling machines or auxiliary axes. C axis on lathes Typical requirements: Various hollow-shaft diameters Resistant to contamination Simple installation Suitable encoder ERM 200 series Possibly the ERM 2200 series For years, the ERMs have been the preferred encoders for C axes on lathes. Besides their high resistance to contamination, the large inside diameters are also important to allow bar material to be machined without limitations. Because of this design arrangement, the graduation of the ERM is usually on a much larger diameter than the workpiece. Position errors of the encoder therefore affect workpiece accuracy to a correspondingly reduced degree. For example, the position error within one signal period, which is approx. 2 µm on a scale drum with 2048 lines and a diameter of mm, engenders positioning error of only 0.8 µm on a workpiece with diameter 100 mm. A smaller workpiece diameter will have an even better value. The accuracy and reproducibility of the ERM therefore also achieve workpiece accuracy values sufficient for milling operations with lathes (classic C-axis machining). 6

7 Rotary and tilting tables Typical requirements: Medium to high accuracy Large hollow-shaft diameter Resistant to contamination Suitable encoder ERM 2200 series Rotary tables and tilting axes require encoders with high signal quality for position and speed control. Encoders with optical measuring standards, for example the RCN series, fulfill these requirements in an ideal way. For medium accuracy requirements magnetic modular encoders can also be used. Due to their small signal period of 200 µm, the ERM 2200 encoders feature particularly low position error within one signal period and therefore permit relatively high axis speed stability. In addition, the typical advantages of magnetic modular encoders, such as tolerance to contamination and large inside diameters, are very helpful in this application. Spindles on milling machines Typical requirements: High shaft speeds Small mounting space Suitable encoder ERM 2400 series ERM 2900 series Spindles are among the key components of machine tools and significantly influence their function. The spindle properties are determined by design, drives and bearing systems, but also the encoders make a decisive contribution to performance. They have to permit high rotational speeds and be sufficiently sturdy. Speeds of over rpm are no problem for the ERM In addition they fulfill the requirement for compact dimensions. If milling and turning operations are to be performed on one machine, increased requirements for spindle accuracy are the result. On complex workpieces, certain machining movements can be performed only through the interaction of feed axes and spindle positions. For example, when manufacturing a thread, a single-point tool needs to assume a defined angular attitude. Here the ERM 2400 encoders with 400 µm signal period come into use. They have better accuracy behavior and, for example, 600 lines on an outside diameter of mm. This is significantly more than gears with comparable dimensions. 7

8 Properties The ERM magnetic modular encoders from HEIDENHAIN are characterized by the following properties: Insensitive to contamination The encoder in the machine tool is often exposed to heavy loads from cooling lubricants. Particularly with high spindle speeds and large diameters, sealing it becomes very difficult. Here the ERM magnetic modular encoders with their high resistance to contamination are of particular benefit: they can even operate under high humidity, heavy dust loads, and in oily atmospheres. Large hollow shafts in small installation space ERM encoders are characterized by compact dimensions and large inside diameters of up to 410 mm. Larger diameters are available upon request. Simple mounting Mounting the scale drum and scanning head is decidedly simple and requires little adjustment. The scale drum is centered via the centering collar on its inner circumference. The scanning head is easily positioned with respect to the scale drum by means of a spacer foil. If the recommended mounting tolerances are complied with, it is not necessary to inspect the output signals or readjust them. High shaft speeds The scale drums were specially conceived for high shaft speeds. The maximum permissible speeds shown in the specifications also apply for extreme loads. This allows continuous operation at the maximum permissible speed as well as the more demanding reciprocating traverse. Even reciprocating traverse with ongoing braking and acceleration processes, even with direction reversal, can be performed at the maximum permissible speeds. The reciprocation is based on 10 million load reversals and therefore fulfills the requirements for fatigue strength. The ERM is completely quiet in operation, even at maximum speeds. Ancillary noises, such as from gear-tooth systems, do not occur. High signal quality The output signals of the ERM magnetic modular encoders are characterized by high signal quality: Together with the signal period, signal quality is decisive for position error within one signal period. With the magnetic modular encoders, as with many other HEIDENHAIN encoders, this value is significantly better than 1% of the signal period. For the ERM 2200 and ERM 200 series, the position error within one signal period is typically less than 0.5% of the signal period. Purely serial interface Besides the incremental output signals, it is possible to transmit the position information as position values over the EnDat 2.2 interface. The sinusoidal scanning signals are highly interpolated in the scanning head and converted to a position value by the integrated counter function. As with all incremental encoders, the absolute reference is determined with the aid of reference marks. A scale drum with distance-coded reference marks is required on these encoders in order to facilitate homing the encoder. The EnDat 2.2 interface offers a large number of other benefits besides serial transmission of the position value, such as automatic self-configuration, monitoring and diagnostic functions, and high reliability of data transmission. Screen showing the valuation numbers as functional reserves (e.g. with ATS software) ERM scale drums 8

9 Measuring principle Measuring standard HEIDENHAIN encoders incorporate measuring standards of periodic structures known as graduations. Magnetic encoders use a graduation carrier of magnetizable steel alloy. A write head applies strong local magnetic fields in different directions to form a graduation consisting of north poles and south poles (MAGNODUR process). The following grating periods are possible on the circumference: Approx. 200 µm for ERM 2200 Approx. 400 µm for ERM 200, ERM 2400, ERM 2410 Approx µm for ERM 2900 Due to the short distance of effect of electromagnetic interaction and the very narrow scanning gaps required, finer magnetic graduations have significantly tighter mounting tolerances. Magnetic scanning The permanently magnetic MAGNODUR graduation is scanned by magnetoresistive sensors. They consist of resistive tracks whose resistance changes in response to a magnetic field. When a voltage is applied to the sensor and the scale drum moves relative to the scanning head, the flowing current is modulated according to the magnetic field. The special geometric arrangement of the resistive sensors and the manufacture of the sensors on glass substrates ensure a high signal quality. In addition, the large scanning surface allows the signals to be filtered for harmonic waves. These are prerequisites for minimizing position errors within one signal period. A magnetic structure on a separate track produces a reference mark signal. This makes it possible to assign this absolute position value to exactly one measuring step. Magnetoresistive scanning is typically used for medium-accuracy applications, or for where the diameter of the machined part is relatively small compared to the scale drum. Incremental measuring method With the incremental measuring method, the graduation consists of a periodic grating structure. The position information is obtained by counting the individual increments (measuring steps) from some point of origin. The shaft speed is determined through mathematical derivation of the change in position over time. Since an absolute reference is required to ascertain positions, the scale drums are provided with an additional track that bears a reference mark or multiple reference marks. The absolute position on the scale, established by the reference mark, is gated with exactly one measuring step. The reference mark must therefore be scanned to establish an absolute reference or to find the last selected datum. The scale drums of the ERM 2200 and ERM 2410 feature distance-coded reference marks. Here the absolute reference is established by scanning two neighboring reference marks (see Angle for absolute reference in the Specifications). Magnetoresistive scanning principle Measuring standard Scanning reticle Magnetoresistive sensors for B+ and B not shown 9

10 Measuring accuracy The accuracy of angular measurement is mainly determined by the quality of the graduation, the stability of the graduation carrier, the quality of the scanning process, the quality of the signal processing electronics, the eccentricity of the graduation to the bearing, the error of the bearing, and the coupling to the measured shaft. These factors of influence are comprised of encoder-specific error and applicationdependent issues. All individual factors of influence must be considered in order to assess the attainable total accuracy. Encoder-specific error The encoder-specific error is given in the Specifications: Accuracy of graduation Position error within one signal period Accuracy of graduation The accuracy of the graduation ± a results from its quality. This includes the homogeneity and period definition of the graduation, the alignment of the graduation on its carrier, and the stability of the graduation carrier, in order to also ensure accuracy in the mounted condition. The accuracy of the graduation ± a is ascertained under ideal conditions by using a series-produced scanning head to measure position error at positions that are integral multiples of the signal period. Position error within one signal period The position error within one signal period ± u results from the quality of the scanning and for encoders with integrated pulseshaping or counter electronics the quality of the signal-processing electronics. For encoders with sinusoidal output signals, however, the error of signal processing is influenced by the subsequent electronics. The following individual factors influence the result: The size of the signal period The homogeneity and period definition of the graduation The quality of scanning filter structures The characteristics of the detectors The stability and dynamics of further processing of the analog signals These factors of influence are to be considered when specifying position error within one signal period. Position error within one signal period ± u is specified in percent of the signal period. For the ERM magnetic modular encoders with approx. 200 µm or 400 µm, the value is typically better than ± 0.5% of the signal period. You will find the values in the Specifications. Position errors within one signal period already become apparent in very small angular motions and in repeated measurements. They especially lead to speed ripples in the speed control loop. Position errors within one revolution Position error within one signal period Position error Position error within one signal period Position Signal level Position error Signal period 360 elec. 10

11 Application-dependent error The mounting and adjustment of the scanning head drum, in addition to the given encoder-specific error, normally have a significant effect on the accuracy that can be achieved by encoders without integral bearings. Of particular importance are the mounting eccentricity of the graduation and the radial runout of the measured shaft. The application-dependent error values must be measured and calculated individually in order to evaluate the total accuracy. On the other hand, the specified system accuracy for the encoders with integral bearing already includes the error of the bearing and the shaft coupling. (See the Absolute Angle Encoders with Optimized Scanning or Angle Encoders with Integral Bearing brochures.) Errors due to eccentricity of the graduation to the bearing Under normal circumstances, the graduation will have a certain eccentricity relative to the bearing once the ERM s scale drum is mounted. In addition, dimensional and form deviations of the customer s shaft can result in added eccentricity. The following relationship exists between the eccentricity e, the graduation diameter D and the measuring error ¹ϕ (see illustration below): ¹ϕ = ± 412 e D ¹ϕ = Measuring error in (angular seconds) e = Eccentricity of the scale drum to the bearing in µm (1/2 the radial deviation) D = Scale-drum diameter (= drum outside diameter) in mm M = Center of graduation ϕ = True angle ϕ = Scanned angle Error due to radial runout of the bearing The equation for the measuring error ¹ϕ is also valid for radial deviation of the bearing if the value e is replaced with the eccentricity value, i.e. half of the radial deviation (half of the displayed value). Bearing compliance to radial shaft loading causes similar errors. Deformation of the graduation Error due to deformation of the graduation is not to be ignored. It occurs when the graduation is mounted on an uneven, for example convex, surface. However, the graduation can also be deformed solely by screw tightening torque. The scale drums of the ERM 2200, ERM 200 and ERM 2410 are particularly rigid in order to prevent this effect. Eccentricity of the graduation to the bearing Resultant measured deviations ¹ϕ for various eccentricity values e as a function of graduation diameter D Scanning unit Measuring error ¹ϕ [angular seconds] Graduation diameter D [mm] 11

12 Calibration chart HEIDENHAIN prepares individual calibration charts and ships them with each of its ERM 2200 series magnetic modular encoders. The calibration chart documents the graduation accuracy including the graduation carrier. It is ascertained through a large number of measuring points during one revolution. All measured values lie within the graduation accuracy listed in the specifications. The calibration standard indicated in the manufacturer s inspection certificate documents and guarantees traceability to recognized national and international standards. Qualitätsprüf-Zertifikat DIN Positionsabweichung Δϕ ["] Position error Δϕ ["] Quality Inspection Certificate DIN Teilungstrommel ERM 2200 C ID SN The accuracy data of the calibration chart do not include the position error within one signal period and any error resulting from mounting. Nullposition / Zero Position Messposition ϕ M [ ] / Measured position ϕ M [ ] Reversal error The reversal error is an effect that occurs when the direction of movement changes. It depends on the size of the signal period and the mounting conditions. With ideal mounting conditions it is approx. 0.5% of the signal period. Deviations of the scanning gap from the nominal value likewise influence the reversal error. HEIDENHAIN therefore recommends measuring the value after mounting for compensation. Die Messkurve zeigt die Positionsabweichungen der Teilung (inkl. Teilungsträger) bei einer Umdrehung. Die Strichzahl der Teilungstrommel beträgt Kundenseitige Abweichungen durch Anbau und Lagerung sind zusätzlich zu berücksichtigen. Positionsabweichung Δϕ des Messgerätes: Δϕ = ϕ S ϕ M ϕ S = Messposition des Vergleichsnormals ϕ M = Messposition des Prüflings Maximale Positionsabweichung der Messkurve innerhalb 360 ± 1,59" Unsicherheit der Messmaschine 0,05 Messparameter Messgeschwindigkeit 3,33 min 1 Anzahl der Messpositionen pro Umdrehung 4096 Dieses Winkelmessgerät wurde unter den strengen HEIDENHAIN- Qualitätsnormen hergestellt und geprüft. Die Positions abweichung liegt bei einer Bezugstemperatur von 22 C innerhalb der Genauigkeitsklasse ± 3,5". The error curve shows the position errors in one revolution of the graduation (incl. graduation carrier). The line count of the angle encoder is Errors at the costumer resulting from mounting and the bearing must also be accounted for. Position error Δϕ of the encoder: Δϕ = ϕ S ϕ M ϕ S = position measured by the reference standard ϕ M = position measured by the measured encoder Maximum position error of the error curve within 360 ± 1.59" Uncertainty of measuring machine 0.05 Measurement parameters Measurement velocity 3.33 min 1 Number of measurement positions per revolution 4096 This angle encoder has been manufactured and inspected in accordance with the stringent quality standards of HEIDENHAIN. The position error at a reference temperature of 22 C lies within the accuracy grade ± 3.5. Kalibriernormal Kalibrierzeichen ERP DKD-K Calibration standard Calibration reference ERP DKD-K DR. JOHANNES HEIDENHAIN GmbH Traunreut, Germany Telefon: +49 (8669) 31-0 Fax: +49 (8669) Prüfer/Inspected by H. Knobloch 12

13 Mechanical design types and mounting The ERM modular encoders consist of a circumferential scale drum and the corresponding scanning head. The assemblies of the scanning head and graduation relative to each other is determined solely via the machine bearing. However, special design features of the ERM modular encoders assure comparably fast mounting and easy adjustment. The data for graduation accuracy and the position error within one signal period can be attained in the application if the requirements are fulfilled (see Specifications). Versions There are various signal periods available for the ERM modular magnetic encoders (ERM 2200: approx. 200 µm, ERM 200/ 2400: approx. 400 µm, ERM 2900: approx. 1 mm). This results in different line counts for the same outside diameter. The scale drums are available in three versions. They differ essentially in the type of mounting. All scale drums feature a centering collar on the inside diameter. TTR ERM 2200 and TTR ERM 200 scale drums For mounting, the scale drums are slid onto the mating shaft and fastened axially with screws. TTR ERM 2x0x scale drum The TTR ERM 2404, TTR ERM 2405 and TTR ERM 2904 scale drums are fastened only by a friction-locked connection to the mating surface. The clamping of the scale drum depends on the mounting situation. The clamping force must be applied evenly over the plane surface of the drum. The necessary mounting elements depend on the design of the customer s equipment, and are therefore the responsibility of the customer. The frictional connection must be strong enough to prevent unintentional rotation or skewing in axial and radial directions, even at high speeds and accelerations. The scale drum must not be modified for this purpose, such as by drilling holes or countersinks in it. The TTR ERM 2404 and TTR ERM 2904 versions feature a smooth inside drum surface. Only a friction-locked connection (clamping of the drum) is to be used to prevent them from rotating unintentionally. The TTR ERM 2405 scale drums feature a keyway. The feather key is intended only for the prevention of unintentional rotation and not for the transmission of torque. The special shape of the drum s inside ensures stability even at the maximum permissible speeds. Centering the scale drum Because the attainable total accuracy is dominated by mounting error (mainly through eccentricity), special attention must be placed on centering the scale drum. Depending on the encoder and mounting method, various methods of centering the scale drums are possible in order to minimize the eccentricity errors that occur in practice. 1. Centering by centering collar The scale drum is pushed or shrunk onto the shaft. This very simple method requires an exact shaft geometry and bearing quality to meet the corresponding accuracy requirements. Mounting of the scale drum TTR ERM 200 TTR ERM 2200 Mounting of the scale drum TTR ERM 2404 TTR ERM 2904 Mounting of the scale drum TTR ERM

14 The scale drum is centered via the centering collar on its inner circumference. HEIDENHAIN recommends a slight oversize of the shaft on which the scale drum is to be mounted. For easier mounting, the scale drum may be slowly warmed on a heating plate over a period of approx. 10 minutes to a temperature of at most 100 C. In order to check the radial runout and assess the resulting deviations, testing of the rotational accuracy before mounting is recommended. Back-off threads are used for dismounting the scale drums. 2. Centering with two scanning heads This method is suited for scale drums with screw fastening. Here the graduation or the position value itself serves as reference. The two scanning heads are connected with the subsequent electronics, which form the difference of the two position values. This centering method is recommended when high accuracy is required or when error caused by the shaft geometry or the bearing is to be avoided. Mounting the scanning head In order to mount the scanning head, the spacer foil is applied to the surface of the circumferential scale drum. The scanning head is pressed against the foil and fastened. The foil is then removed. Test film for magnetic graduation The test film is used to make the magnetic graduation visible. It enables the user to easily check whether there is any damage to the magnetic graduation, such as demagnetization from a tool. The test film can be cleaned with the aid of a demagnetization device and therefore used repeatedly. The test film and demagnetization device are available as accessories. Mounting clearance The mounting clearance (gap between scanning head and scale drum) depends on the encoder s signal period. As a result, the spacer foils for mounting the scanning head are of varying thicknesses. Deviations of the scale-to-reticle gap from the ideal value negatively influence the signal amplitude. Measuring with two scanning heads Error caused by the eccentricity of the graduation to the bearing are compensated with the aid of a second scanning head that is arranged at an angle of 180 ± 5 to the first one. The incremental signals of both scanning heads are digitally offset in an external EIB 1500 interface box with a high subdivision factor and are transmitted as absolute position values after the reference mark is scanned. (See Product Information EIB 1500). Signal amplitude [VPP] approx. 200 µm 400 µm µm Change in scanning gap [µm] Centering with two scanning heads Mounting the scanning head, e.g. AK ERM 280 Typical correlation of signal amplitude and scanning gap (mounting clearance) 14

15 General mechanical information Protection against contact After encoder installation, all rotating parts must be protected against accidental contact during operation. Acceleration Encoders are subject to various types of acceleration during operation and mounting. The indicated maximum values for vibration are valid according to EN The maximum permissible acceleration values (semi-sinusoidal shock) for shock and impact are valid for 6 ms (EN ). Under no circumstances should a hammer or similar implement be used to adjust or position the encoder. Temperature range The operating temperature range indicates the ambient temperature limits between which the encoders will function properly. The storage temperature range from 30 C to +70 C is valid as long as the unit remains in its packaging. Rotational velocity The maximum permissible shaft speeds were determined according to FKM guidelines. This guideline serves as mathematical attestation of component strength with regard to all relevant influences and it reflects the latest state of the art. The requirements for fatigue strength (10 million reversals of load) were considered in the calculation of the permissible shaft speeds. Because installation has significant influence, all requirements and directions in the specifications and mounting instructions must be followed for the rotational velocity data to be valid. Expendable parts HEIDENHAIN encoders contain components that are subject to wear, depending on the application and handling. These include in particular moving cables. Pay attention to the minimum permissible bending radii. Mounting Work steps to be performed and dimensions to be maintained during mounting are specified solely in the mounting instructions supplied with the unit. All data in this catalog regarding mounting are therefore provisional and not binding; they do not become terms of a contract. System tests Encoders from HEIDENHAIN are usually integrated as components in larger systems. Such applications require comprehensive tests of the entire system regardless of the specifications of the encoder. The specifications shown in this brochure apply to the specific encoder, not to the complete system. Any operation of the encoder outside of the specified range or for any other than the intended applications is at the user s own risk. In safety-related systems, the higherlevel system must verify the position value of the encoder after switch-on. Protection against contact 15

16 ERM 2200 series Modular encoders with magnetic scanning principle Signal period approx. 200 µm (at circumference) For rotary and tilting tables A = À = Á = Â = Bearing Mounting distance of 0.05 mm set with spacer foil Marker for reference mark, position tolerance with respect to reference mark ± 5 Direction of shaft rotation for output signals according to interface description D1 W D2 D3 E G 70 0/ / / / / / / / / / / / x M6 6x M6 6x M6 6x M6 6x M6 12x M6 16

17 Scanning head AK ERM 2280 Incremental signals Cutoff frequency 3 db» 1 V PP 300 khz Signal period Approx. 200 µm Line count* See Scale drum Power supply 5 V DC ± 10 % Current consumption Electrical connection* Cable length Vibration 55 to 2000 Hz Shock 6 ms 150 ma (without load) Cable 1 m, with or without coupling 150 m (with HEIDENHAIN cable) 400 m/s 2 (EN ) 1000 m/s 2 (EN ) Operating temperature 10 C to 60 C Protection EN IP 67 Weight Approx kg (with cable) Scale drum TTR ERM 2200 C Measuring standard MAGNADUR graduation; signal period of approx. 200 µm Inside diameter* 70 mm 80 mm 130 mm 180 mm 260 mm 380 mm Outside diameter mm mm mm mm mm mm Line count* Position error per signal ± 5.5 ± 4.5 ± 3.5 ± 2.5 ± 2 ± 1.5 period 1) Accuracy of graduation ± 7 ± 6 ± 5 ± 3.5 ± 3 ± 2.5 Reference mark Angle for absolute reference Distance-coded Mech. permissible speed min min min min min min 1 Moment of inertia of the rotor Permissible axial motion kgm kgm kgm kgm kgm kgm 2 ± 1.25 mm Weight approx kg 0.89 kg 1.2 kg 3.0 kg 3.5 kg 5.4 kg * Please select or indicate when ordering 1) The position error within one signal period and the accuracy of the graduation result together in the encoder-specific error; for additional error through mounting and the bearing of the measured shaft, see Measuring accuracy Other line counts/dimensions upon request 17

18 ERM 200 series Modular encoders with magnetic scanning principleple Signal period approx. 400 µm (at circumference) For C axis on lathes A = Bearing À = Mounting distance of 0.15 mm set with spacer foil Á = Marker for reference mark, position tolerance with respect to reference mark ± 5 Â = Direction of shaft rotation for output signals according to interface description 18

19 Scanning head AK ERM 220 AK ERM 280 Incremental signals «TTL» 1 V PP Cutoff frequency 3 db Scanning frequency 350 khz 300 khz Signal period Approx. 400 µm Line count* See Scale drum Power supply 5 V DC ± 10 % Current consumption Electrical connection* 150 ma (without load) Cable 1 m, with or without coupling Cable length 100 m (with HEIDENHAIN cable) 150 m (with HEIDENHAIN cable) Vibration 55 to 2000 Hz Shock 6 ms 400 m/s 2 (EN ) 1000 m/s 2 (EN ) Operating temperature 10 C to 100 C Protection EN IP 67 Weight Approx kg (with cable) Scale drum TTR ERM 200 Measuring standard MAGNADUR graduation; signal period of approx. 400 µm Inside diameter* 40 mm 70 mm 80 mm 120 mm 130 mm 180 mm 220 mm 295 mm 410 mm Outside diameter mm mm mm mm mm mm mm mm mm Line count* Position error per signal ± 15.5 ± 10.5 ± 9 ± 8 ± 6.5 ± 4.5 ± 4.5 ± 3.5 ± 3 period 1) Accuracy of graduation ± 11 ± 8 ± 7 ± 6 ± 5.5 ± 4 ± 5 ± 4 ± 3.5 Reference mark* TTR ERM 200: One TTR ERM 200 C: Distance-coded Mech. permissible speed min 1 min 1 min 1 min 1 min 1 min 1 min 1 min 1 min 1 Moment of inertia of the rotor Permissible axial motion kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 ± 1.25 mm Weight approx kg 0.69 kg 0.89 kg 0.72 kg 1.2 kg 3.0 kg 1.6 kg 1.7 kg 3.2 kg * Please select or indicate when ordering 1) The position error within one signal period and the accuracy of the graduation result together in the encoder-specific error; for additional error through mounting and the bearing of the measured shaft, see Measuring accuracy Other line counts/dimensions upon request 19

20 ERM 2410 series Modular encoders with magnetic scanning principle For C axis on lathes Integrated counting function for position-value output Absolute position value after traverse of two reference marks C A = Bearing À = Mounting distance of 0.15 mm set with spacer foil Á = Marker for reference mark, position tolerance with r espect to reference mark ± 5 Â Direction of shaft rotation for output signals according to interface description 20

21 Scanning head AK ERM 2410 Interface EnDat 2.2 (absolute position value after scanning two reference marks in position value 2 ) Ordering designation EnDat 22 Integrated interpolation Clock frequency fold (14 bits) 8 MHz Calculation time t cal 5 µs Signal period Approx. 400 µm Line count* Power supply Power consumption 1) Current consumption (typ.) Electrical connection Cable length Vibration 55 to 2000 Hz Shock 6 ms See Scale drum 3.6 to 14 V DC At 14 V: 110 ma; at 3.6 V: 300 ma (maximum) At 5 V: 90 ma (without load) Cable, 1 m, with M12 coupling (8-pin) 150 m (with HEIDENHAIN cable) 300 m/s 2 (EN ) 1000 m/s 2 (EN ) Operating temperature 10 C to 100 C Protection EN IP 67 Weight Approx kg (with cable) Scale drum TTR ERM 200 C Measuring standard MAGNADUR graduation, signal period approx. 400 µm Inside diameter* 40 mm 70 mm 80 mm 120 mm 130 mm 180 mm 220 mm 295 mm 410 mm Outside diameter mm mm mm mm mm mm mm mm mm Line count* Positions per revolution Position error per signal ± 15.5 ± 10.5 ± 9 ± 8 ± 6.5 ± 4.5 ± 4.5 ± 3.5 ± 3 period 1) Accuracy of the ± 11 ± 8 ± 7 ± 6 ± 5.5 ± 4 ± 5 ± 4 ± 3.5 graduation 2) Reference marks Distance-coded Angle for absolute reference Mech. permiss. speed min 1 min 1 min 1 min 1 min 1 min 1 min 1 min 1 min 1 Moment of inertia of the rotor Permissible axial motion kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 kgm 2 ± 1.25 mm Weight approx kg 0.69 kg 0.89 kg 0.72 kg 1.2 kg 3.0 kg 1.6 kg 1.7 kg 3.2 kg * Please select when ordering 1) See General Electrical Information 2) The position error within one signal period and the accuracy of the graduation result together in the encoder-specific error; for additional error through mounting and the bearing of the measured shaft, see Measuring accuracy Other line counts/dimensions upon request 21

22 ERM 2400 series Modular encoders with magnetic scanning principle Signal period approx. 400 µm (at circumference) For spindles on milling machines ERM 2404 scale drum ERM 2405 scale drum A = Bearing À = Mounting distance of 0.15 mm set with spacer foil Á = Marker for reference mark, position tolerance with respect to reference mark ± 5  = Direction of shaft rotation for output signals as per the interface description à = Centering collar Ä = Clamping area (applies to both sides) Å = Slot for feather key 4 x 4 x 10 (as per DIN 6885 shape A) D / / / / W D2 E 40 0/ Ø 55 0/ Ø 80 0/ Ø 100 0/

23 Scanning head AK ERM 2480 Incremental signals Cutoff frequency 3 db» 1 V PP 300 khz Signal period Approx. 400 µm Line count* See Scale drum Power supply 5 V DC ± 10 % Current consumption Electrical connection* Cable length Vibration 55 to 2000 Hz Shock 6 ms 150 ma (without load) Cable 1 m, with or without coupling; cable outlet axial or radial 150 m (with HEIDENHAIN cable) 400 m/s 2 (EN ) 1000 m/s 2 (EN ) Operating temperature 10 C to 100 C Protection EN IP 67 Weight Approx kg (with cable) Scale drum ERM 2404 ERM 2405 Measuring standard MAGNADUR graduation; signal period of approx. 400 µm Inside diameter* 40 mm 55 mm 80 mm 100 mm 40 mm 55 mm Outside diameter mm mm mm mm mm mm Line count* Position error per signal ± 18 ± 15.5 ± 10.5 ± 9 ± 18 ± 15.5 period 1) Accuracy of graduation ± 17 ± 14 ± 10 ± 9 ± 17 ± 14 Reference mark One Mech. permissible speed min min min min min min 1 Moment of inertia of the rotor Permissible axial motion kgm kgm kgm kgm kgm kgm 2 ± 0.5 mm Weight approx kg 0.17 kg 0.42 kg 0.43 kg 0.15 kg 0.15 kg * Please select or indicate when ordering 1) The position error within one signal period and the accuracy of the graduation result together in the encoder-specific error; for additional error through mounting and the bearing of the measured shaft, see Measuring accuracy Other line counts/dimensions upon request 23

24 ERM 2900 series Modular encoders with magnetic scanning principle Signal period approx µm (at circumference) For spindles on milling machines A = Bearing À = Mounting distance of 0.30 mm set with spacer foil Á = Marker for reference mark, position tolerance with respect to reference mark ± 5  = Direction of shaft rotation for output signals as per the interface description à = Centering collar Ä = Clamping area (applies to both sides) D / / / / W D2 E 40 0/ Ø 55 0/ Ø 60 0/ Ø 100 0/

25 Scanning head AK ERM 2980 Incremental signals Cutoff frequency 3 db» 1 V PP 300 khz Signal period Approx µm Line count* See Scale drum Power supply 5 V DC ± 10 % Current consumption Electrical connection* Cable length Vibration 55 to 2000 Hz Shock 6 ms 150 ma (without load) Cable 1 m, with or without coupling; cable outlet axial or radial 150 m (with HEIDENHAIN cable) 400 m/s 2 (EN ) 1000 m/s 2 (EN ) Operating temperature 10 C to 100 C Protection EN IP 67 Weight Approx kg (with cable) Scale drum ERM 2904 Measuring standard MAGNADUR graduation; signal period of approx µm Inside diameter* 40 mm 55 mm 60 mm 100 mm Outside diameter mm mm mm mm Line count* Position error per signal ± 68 ± 51 ± 44 ± 33 period 1) Accuracy of graduation ± 68 ± 51 ± 44 ± 33 Reference mark One Mech. permissible speed min min min min 1 Moment of inertia of the rotor Permissible axial motion kgm kgm kgm kgm 2 ± 0.5 mm Weight approx kg 0.19 kg 0,30 kg 0,30 kg * Please select or indicate when ordering 1) The position error within one signal period and the accuracy of the graduation result together in the encoder-specific error; for additional error through mounting and the bearing of the measured shaft, see Measuring accuracy Other line counts/dimensions upon request 25

26 Interfaces Incremental signals» 1 V PP HEIDENHAIN encoders with» 1 V PP interface provide voltage signals that can be highly interpolated. The sinusoidal incremental signals A and B are phase-shifted by 90 elec. and have an amplitude of typically 1 V PP. The illustrated sequence of output signals with B lagging A applies for the direction of motion shown in the dimension drawing. The reference mark signal R has a usable component G of approx. 0.5 V. Next to the reference mark, the output signal can be reduced by up to 1.7 V to a quiescent level H. This must not cause the subsequent electronics to overdrive. Even at the lowered signal level, signal peaks with the amplitude G can also appear. The data on signal amplitude apply when the power supply given in the specifications is connected to the encoder. They refer to a differential measurement at the 120 ohm terminating resistor between the associated outputs. The signal amplitude decreases with increasing frequency. The cutoff frequency indicates the scanning frequency at which a certain percentage of the original signal amplitude is maintained: 3 db ƒ 70 % of the signal amplitude 6 db ƒ 50 % of the signal amplitude Interface Incremental signals Reference mark signal Connecting cable Cable length Propagation time Sinusoidal voltage signals» 1 V PP 2 nearly sinusoidal signals A and B Signal amplitude M: 0.6 to 1.2 V PP ; typically 1 V PP Asymmetry P N /2M: Amplitude ratio M A /M B : 0.8 to 1.25 Phase angle ϕ1 + ϕ2 /2: 90 ± 10 elec. One or several signal peaks R Usable component G: 0.2 V Quiescent value H: 1.7 V Switching threshold E, F: 0.04 to 0.68 V Zero crossovers K, L: 180 ± 90 elec. Shielded HEIDENHAIN cable For example PUR [4(2 x 0.14 mm 2 ) + (4 x 0.5 mm 2 )] Max. 150 m at 90 pf/m distributed capacitance 6 ns/m These values can be used for dimensioning of the subsequent electronics. Any limited tolerances in the encoders are listed in the specifications. For encoders without integral bearing, reduced tolerances are recommended for initial operation (see the mounting instructions). Signal period 360 elec. The data in the signal description apply to motions at up to 20% of the 3 db cutoff frequency. Interpolation/resolution/measuring step The output signals of the 1 V PP interface are usually interpolated in the subsequent electronics in order to attain sufficiently high resolutions. For velocity control, interpolation factors are commonly over 1000 in order to receive usable information even at low rotational or linear velocities. Measuring steps for position measurement are recommended in the specifications. For special applications, other resolutions are also possible. (rated value) A, B, R measured with oscilloscope in differential mode Alternative signal shape Short-circuit stability A temporary short circuit of one signal output to 0 V or U P (except encoders with U Pmin = 3.6 V) does not cause encoder failure, but it is not a permissible operating condition. Short circuit at 20 C 125 C One output < 3 min < 1 min Cutoff frequency Typical signal amplitude curve with respect to the scanning frequency (depends on encoder) Signal amplitude [%] All outputs < 20 s < 5 s 26 3 db cutoff frequency 6 db cutoff frequency Scanning frequency [khz]

27 Input circuitry of subsequent electronics Incremental signals Reference mark signal Encoder Subsequent electronics Dimensioning Operational amplifier MC Z 0 = 120 R 1 = 10 k and C 1 = 100 pf R 2 = 34.8 k and C 2 = 10 pf U B = ±15 V U 1 approx. U 0 R a < 100, typ. 24 C a < 50 pf ΣI a < 1 ma U 0 = 2.5 V ± 0.5 V (relative to 0 V of the power supply) 3 db cutoff frequency of circuitry Approx. 450 khz Approx. 50 khz with C 1 = 1000 pf and C 2 = 82 pf The circuit variant for 50 khz does reduce the bandwidth of the circuit, but in doing so it improves its noise immunity. Encoders with higher signal frequencies (e.g. LIP 281) require special input circuitry (see the Exposed Linear Encoders brochure). Circuit output signals U a = 3.48 V PP typically Gain 3.48 Monitoring of the incremental signals The following thresholds are recommended for monitoring of the signal level M: Lower threshold: 0.30 V PP Upper threshold: 1.35 V PP Pin layout 12-pin coupling, M23 12-pin connector, M23 15-pin D-sub connector For HEIDENHAIN controls and IK pin D-sub connector For encoders or IK 215 Power supply Incremental signals Other signals / /8/13/15 14 / /6/8/15 13 / U P Sensor 0 V Sensor U P 0 V A+ A B+ B R+ R Vacant Vacant Vacant Brown/ Green Blue White/ Green White Brown Green Gray Pink Red Black / Violet Yellow Cable shield connected to housing; U P = Power supply voltage Sensor: The sensor line is connected in the encoder with the corresponding power line. Vacant pins or wires must not be used! 27

28 Interfaces Incremental signals «TTL HEIDENHAIN encoders with «TTL interface incorporate electronics that digitize sinusoidal scanning signals with or without interpolation. Interface Incremental signals Square-wave signals «TTL 2 square-wave signals U a1, U a2 and their inverted signals, The incremental signals are transmitted as the square-wave pulse trains U a1 and U a2, phase-shifted by 90 elec. The reference mark signal consists of one or more reference pulses U a0, which are gated with the incremental signals. In addition, the integrated electronics produce their inverted signals, and for noise-proof transmission. The illustrated sequence of output signals with U a2 lagging U a1 applies to the direction of motion shown in the dimension drawing. The fault-detection signal indicates fault conditions such as breakage of the power line or failure of the light source. It can be used for such purposes as machine shut-off during automated production. Reference mark signal Pulse width Delay time Fault-detection signal Pulse width Signal amplitude 1 or more TTL square-wave pulses U a0 and their inverted pulses 90 elec. (other widths available on request) t d 50 ns 1 TTL square-wave pulse Improper function: LOW (upon request: U a1 /U a2 high impedance) Proper function: HIGH t S 20 ms Differential line driver as per EIA standard RS-422 U H 2.5 V at I H = 20 ma ERN 1x23: 10 ma U L 0.5 V at I L = 20 ma ERN 1x23: 10 ma Permissible load Z Between associated outputs I L 20 ma Max. load per output (ERN 1x23: 10 ma) C load 1000 pf With respect to 0 V Outputs protected against short circuit to 0 V The distance between two successive edges of the incremental signals U a1 and U a2 through 1-fold, 2-fold or 4-fold evaluation is one measuring step. The subsequent electronics must be designed to detect each edge of the square-wave pulse. The minimum edge separation a listed in the Specifications applies to the illustrated input circuitry with a cable length of 1 m, and refers to a measurement at the output of the differential line receiver. Propagation-time differences in cables additionally reduce the edge separation by 0.2 ns per meter of cable length. To prevent counting errors, design the subsequent electronics to process as little as 90 % of the resulting edge separation. The max. permissible shaft speed or traversing velocity must never be exceeded. Switching times (10% to 90%) Connecting cable Cable length Propagation time t + / t 30 ns (typically 10 ns) with 1 m cable and recommended input circuitry Shielded HEIDENHAIN cable For example PUR [4( mm 2 ) + (4 0.5 mm 2 )] Max. 100 m ( max. 50 m) at distributed capacitance 90 pf/m 6 ns/m Signal period 360 elec. Measuring step after 4-fold evaluation Fault Inverse signals,, are not shown The permissible cable length for transmission of the TTL square-wave signals to the subsequent electronics depends on the edge separation a. It is at most 100 m, or 50 m for the fault detection signal. This requires, however, that the power supply (see Specifications) be ensured at the encoder. The sensor lines can be used to measure the voltage at the encoder and, if required, correct it with an automatic control system (remote sense power supply). Permissible cable length with respect to the edge separation Cable length [m] Without With Edge separation [µs] 28

29 Input circuitry of subsequent electronics Incremental signals Reference mark signal Encoder Subsequent electronics Dimensioning IC 1 = Recommended differential line receiver DS 26 C 32 AT Only for a > 0.1 µs: AM 26 LS 32 MC 3486 SN 75 ALS 193 Fault-detection signal R 1 = 4.7 k R 2 = 1.8 k Z 0 = 120 C 1 = 220 pf (serves to improve noise immunity) Pin layout 12-pin coupling, M23 12-pin connector, M23 15-pin D-sub connector For HEIDENHAIN controls and IK pin D-sub connector For encoders or IK 215 Power supply Incremental signals Other signals / /8/ /6/8 15 U P Sensor 0 V Sensor U P 0 V U a1 U a2 U a0 1) Vacant Vacant 2) Brown/ Green Blue White/ Green White Brown Green Gray Pink Red Black Violet / Yellow Cable shield connected to housing; U P = Power supply voltage Sensor: The sensor line is connected in the encoder with the corresponding power line. Vacant pins or wires must not be used! 1) ERO 14xx: Vacant 2) Exposed linear encoders: Switchover TTL/11 µapp for PWT, otherwise vacant 29

30 Interfaces Absolute position values The EnDat interface is a digital, bidirectional interface for encoders. It is capable both of transmitting position values as well as transmitting or updating information stored in the encoder, or saving new information. Thanks to the serial transmission method, only four signal lines are required. The data is transmitted in synchronism with the clock signal from the subsequent electronics. The type of transmission (position values, parameters, diagnostics, etc.) is selected through mode commands that the subsequent electronics send to the encoder. Some functions are available only with EnDat 2.2 mode commands. Interface Data transfer Data input Data output Position values Incremental signals EnDat serial bidirectional Absolute position values, parameters and additional information Differential line receiver according to EIA standard RS 485 for the signals CLOCK, CLOCK, DATA and DATA Differential line driver according to EIA standard RS 485 for the signals DATA and DATA Ascending during traverse in direction of arrow (see dimensions of the encoders)» 1 V PP (see Incremental Signals 1 V PP ) depending on the unit For more information, refer to the EnDat Technical Information sheet or visit www. endat.de. Position values can be transmitted with or without additional information (e.g. position value 2, temperature sensors, diagnostics, limit position signals). Besides the position, additional data can be interrogated in the closed loop and functions can be performed with the EnDat 2.2 interface. Ordering designation EnDat 01 EnDat 21 Command set EnDat 2.1 or EnDat 2.2 Incremental signals With Without Power supply See specifications of the encoder EnDat 02 EnDat 2.2 With Extended range 3.6 to 5.25 V DC or EnDat 22 EnDat 2.2 Without 14 V DC Versions of the EnDat interface (bold print indicates standard versions) Parameters are saved in various memory areas, e.g.: Encoder-specific information Information of the OEM (e.g. electronic ID label of the motor) Operating parameters (datum shift, instruction, etc.) Operating status (alarm or warning messages) Monitoring and diagnostic functions of the EnDat interface make a detailed inspection of the encoder possible. Error messages Warnings Online diagnostics based on valuation numbers (EnDat 2.2) Incremental signals EnDat encoders are available with or without incremental signals. EnDat 21 and EnDat 22 encoders feature a high internal resolution. An evaluation of the incremental signal is therefore unnecessary. Clock frequency and cable length The clock frequency is variable depending on the cable length (max. 150 m) between 100 khz and 2 MHz. With propagation-delay compensation in the subsequent electronics, either clock frequencies up to 16 MHz are possible or cable lengths up to 100 m (for other values see Specifications). 30 Operating parameters Cable length [m] Operating status Absolute encoder Parameters of the OEM Incremental signals *) Absolute position value Parameters of the encoder manufacturer for EnDat 2.1 EnDat 2.2 Subsequent electronics» 1 V PP A*)» 1 V PP B*) *) Depends on encoder Clock frequency [khz] EnDat 2.1; EnDat 2.2 without propagation-delay compensation EnDat 2.2 with propagation-delay compensation EnDat interface

31 Input circuitry of subsequent electronics Data transfer Encoder Subsequent electronics Dimensioning IC 1 = RS 485 differential line receiver and driver C 3 = 330 pf Z 0 = 120 Incremental signals Depending on encoder 1 V PP Pin layout 8-pin coupling, M12 Power supply Absolute position values U P Sensor U P 0 V Sensor 0 V DATA DATA CLOCK CLOCK Brown/Green Blue White/Green White Gray Pink Violet Yellow 17-pin coupling, M23 15-pin D-sub connector For HEIDENHAIN controls and IK 220 Power supply Incremental signals 1) Absolute position values U P Sensor 0 V Sensor U P 0 V Internal shield A+ A B+ B DATA DATA CLOCK CLOCK Brown/ Green Blue White/ Green White / Green/ Black Yellow/ Black Blue/ Black Red/ Black Gray Pink Violet Yellow Cable shield connected to housing; U P = Power supply voltage Sensor: The sensor line is connected in the encoder with the corresponding power line. Vacant pins or wires must not be used! 1) Only with ordering designations EnDat 01 and EnDat 02 31

32 Cables and connecting elements General information Connector (insulated): A connecting element with a coupling ring. Available with male or female contacts. Symbols Coupling (insulated): Connecting element with external thread; available with male or female contacts. Symbols M12 M23 M12 M23 Mounted coupling with central fastening Cutout for mounting M23 Mounted coupling with flange M23 Flange socket: Permanently mounted on a housing, with external thread (like a coupling), and available with male or female contacts. Symbols M23 The pins on connectors are numbered in the direction opposite to those on couplings or flange sockets, regardless of whether the connecting elements have male or female contacts. When engaged, the connections are protected to IP 67 (D-sub connector: IP 50; EN ). When not engaged, there is no protection. Accessories for flange sockets and M23 mounted couplings Bell seal ID Threaded metal dust cap ID D-sub connector: For HEIDENHAIN controls, counters and IK absolute value cards. Symbols 1) With integrated interpolation electronics 32

33 Connecting cables 8-pin 17-pin M12 M23 For EnDat without incremental signals For» 1 V PP «TTL PUR connecting cables 8-pin: [( mm 2 ) + ( mm 2 )] 6 mm 12-pin: [4( mm 2 ) + (4 0.5 mm 2 )] 8 mm Complete with connector (female) and coupling (male) Complete with connector (female) and connector (male) Complete with connector (female) and D-sub connector (female) for IK 220 Complete with connector (female) and D-sub connector (male) for IK 115/IK xx xx xx xx xx xx xx With one connector (female) xx xx Cable without connectors, 8 mm Mating element on connecting cable to connector on encoder cable Connector (female) for cable 8 mm Connector on connecting cable for connection to subsequent electronics Connector (male) for cable 8 mm 6 mm Coupling on connecting cable Coupling (male) for cable 4.5 mm 6 mm 8 mm Flange socket for mounting on the subsequent electronics Flange socket (female) Mounted couplings With flange (female) 6 mm 8 mm With flange (male) 6 mm 8 mm With central fastening (male) 6 to 10 mm Adapter» 1 V PP /11 µa PP For converting the 1 V PP signals to 11 µa PP ; 12-pin M23 connector (female) and 9-pin M23 connector (male)

34 General electrical information Power supply Connect HEIDENHAIN encoders only to subsequent electronics whose power supply is generated from PELV systems (EN ). In addition, overcurrent protection and overvoltage protection are required in safety-related applications. If HEIDENHAIN encoders are to be operated in accordance with IEC , power must be supplied from a secondary circuit with current or power limitation as per IEC :2001, section 9.3 or IEC :2005, section 2.5 or a Class 2 secondary circuit as specified in UL1310. The encoders require a stabilized DC voltage U P as power supply. The respective Specifications state the required power supply and the current consumption. The permissible ripple content of the DC voltage is: High frequency interference U PP < 250 mv with du/dt > 5 V/µs Low frequency fundamental ripple U PP < 100 mv The values apply as measured at the encoder, i.e., without cable influences. The voltage can be monitored and adjusted with the encoder s sensor lines. If a controllable power supply is not available, the voltage drop can be halved by switching the sensor lines parallel to the corresponding power lines. Calculation of the voltage drop: ¹U = L C I 56 A P where ¹U: Voltage drop in V 1.05: Length factor due to twisted wires L C : Cable length in m I: Current consumption in ma A P : Cross section of power lines in mm 2 The voltage actually applied to the encoder is to be considered when calculating the encoder s power requirement. This voltage consists of the supply voltage U P provided by the subsequent electronics minus the line drop in the power lines. For encoders with an expanded supply range, the voltage drop in the power lines must be calculated under consideration of the nonlinear current consumption (see next page). If the voltage drop is known, all parameters for the encoder and subsequent electronics can be calculated, e.g. voltage at the encoder, current requirements and power consumption of the encoder, as well as the power to be provided by the subsequent electronics. Switch-on/off behavior of the encoders The output signals are valid no sooner than after switch-on time t SOT = 1.3 s (2 s for PROFIBUS-DP) (see diagram). During time t SOT they can have any levels up to 5.5 V (with HTL encoders up to U Pmax ). If an interpolation electronics unit is inserted between the encoder and the power supply, this unit s switch-on/off characteristics must also be considered. If the power supply is switched off, or when the supply voltage falls below U min, the output signals are also invalid. During restart, the signal Cable Transient response of supply voltage and switch-on/switch-off behavior Output signals invalid level must remain below 1 V for the time t SOT before power on. These data apply to the encoders listed in the catalog customer-specific interfaces are not considered. Encoders with new features and increased performance range may take longer to switch on (longer time t SOT ). If you are responsible for developing subsequent electronics, please contact HEIDENHAIN in good time. Isolation The encoder housings are isolated against internal circuits. Rated surge voltage: 500 V (preferred value as per VDE 0110 Part 1, overvoltage category II, contamination level 2) U PP Valid Cross section of power supply lines A P 1 V PP /TTL/HTL 11 µa PP EnDat/SSI 17-pin Invalid EnDat 5) 8-pin 3.7 mm 0.05 mm mm mm 0.24 mm mm EPG 0.05 mm mm mm mm 5.1 mm 0.14/0.09 2) mm mm /0.14 6) mm ), 3) mm mm mm PVC 0.1 mm 2 6 mm 0.19/0.14 2), 4) mm /0.19 6) mm mm 2 10 mm 1) 8 mm 0.5 mm 2 1 mm mm 2 1 mm 2 14 mm 1) 1) Metal armor 2) Rotary encoders 3) Length gauges 4) LIDA 400 5) Also Fanuc, Mitsubishi 6) RCN, LC adapter cable 34

35 Encoders with expanded supply voltage range For encoders with expanded supply voltage range, the current consumption has a nonlinear relationship with the supply voltage. On the other hand, the power consumption follows a linear curve (see Current and power consumption diagram). The maximum power consumption at minimum and maximum supply voltage is listed in the Specifications. The maximum power consumption (worst case) accounts for: Recommended receiver circuit Cable length 1 m Age and temperature influences Proper use of the encoder with respect to clock frequency and cycle time The typical current consumption at no load (only supply voltage is connected) for 5 V supply is specified. Step 1: Resistance of the supply lines The resistance values of the supply lines (adapter cable and encoder cable) can be calculated with the following formula: R L = L C 56 A P Step 2: Coefficients for calculation of the drop in line voltage b = R L P Emax P Emin U Emax U Emin U P c = P Emin R L + P Emax P Emin U Emax U Emin R L (U P U Emin ) Step 3: Voltage drop based on the coefficients b and c ¹U = 0.5 (b + ¹b 2 4 c) Step 4: Parameters for subsequent electronics and the encoder Voltage at encoder: U E = U P ¹U Current requirement of encoder: I E = ¹U / R L Power consumption of encoder: P E = U E I E Power output of subsequent electronics: P S = U P I E The actual power consumption of the encoder and the required power output of the subsequent electronics are measured, while taking the voltage drop on the supply lines into consideration, in four steps: Where: U Emax, U Emin : Minimum or maximum supply voltage of the encoder in V P Emin, P Emax : Maximum power consumption at minimum or maximum power supply, respectively, in W U P : Supply voltage of the subsequent electronics in V R L : Cable resistance (for both directions) in ohms ¹U: Voltage drop in the cable in V 1.05: Length factor due to twisted wires L C : Cable length in m A P : Cross section of power lines in mm 2 Influence of cable length on the power output of the subsequent electronics (example representation) Current and power consumption with respect to the supply voltage (example representation) Power output of subsequent electronics (normalized) Encoder cable/adapter cable Connecting cable Supply voltage [V] Total Power consumption and current requirement (normalized) Supply voltage [V] Power consumption of encoder (normalized to value at 5 V) Current requirement of encoder (normalized to value at 5 V) 35

36 Electrically permissible speed/ traversing speed The maximum permissible shaft speed or traversing velocity of an encoder is derived from the mechanically permissible shaft speed/traversing velocity (if listed in the Specifications) and the electrically permissible shaft speed/ traversing velocity. For encoders with sinusoidal output signals, the electrically permissible shaft speed/traversing velocity is limited by the 3 db/ 6 db cutoff frequency or the permissible input frequency of the subsequent electronics. For encoders with square-wave signals, the electrically permissible shaft speed/ traversing velocity is limited by the maximum permissible scanning/ output frequency f max of the encoder, and the minimum permissible edge separation a for the subsequent electronics. For angle or rotary encoders n max = f max z For linear encoders v max = f max SP Where: n max : Elec. permissible speed in min 1 v max : Elec. permissible traversing velocity in m/min f max : Max. scanning/output frequency of encoder or input frequency of subsequent electronics in khz z: Line count of the angle or rotary encoder per 360 SP: Signal period of the linear encoder in µm Cables For safety-related applications, use HEIDENHAIN cables and connectors. Versions The cables of almost all HEIDENHAIN encoders and all adapter and connecting cables are sheathed in polyurethane (PUR cables). Many adapter cables for within motors and a few cables on encoders are sheathed in a special elastomer (EPG). Many adapter cables within the motor consist of TPE wires (special thermoplastic) in braided sleeving. Individual encoders feature cable with a sleeve of polyvinyl chloride (PVC). This cables are identified in the catalog as EPG, TPE or PVC. Durability PUR cables are resistant to oil and hydrolysis in accordance with VDE 0472 (Part 803/test type B) and resistant to microbes in accordance with VDE 0282 (Part 10). They are free of PVC and silicone and comply with UL safety directives. The UL certification AWM STYLE C 30 V E63216 is documented on the cable. EPG cables are resistant to oil in accordance with VDE 0472 (Part 803/test type B) and to hydrolysis in accordance with VDE 0282 (Part 10). They are free of PVC, silicone and halogens. In comparison with PUR cables, they are only somewhat resistant to media, frequent flexing and continuous torsion. PVC cables are oil resistant. The UL certification AWM E64638 STYLE C VW-1SC NIKKO is documented on the cable. TPE wires with braided sleeving are oil resistant and highly flexible. Cable Bend radius R Rigid configuration Rigid configuration Frequent flexing Frequent flexing Frequent flexing 3.7 mm 8 mm 40 mm 4.3 mm 10 mm 50 mm 4.5 mm EPG 18 mm 4.5 mm 5.1 mm 5.5 mm PVC 6 mm 10 mm 1) 20 mm 35 mm 8 mm 14 mm 1) 40 mm 100 mm Temperature range Rigid configuration 10 mm 50 mm 75 mm 75 mm 100 mm 100 mm Frequent flexing PUR 40 to 80 C 10 to 80 C EPG TPE 40 to 120 C PVC 20 to 90 C 10 to 90 C PUR cables with limited resistance to hydrolysis and microbes are rated for up to 100 C. If needed, please ask for assistance from HEIDENHAIN Traunreut. Lengths The cable lengths listed in the Specifications apply only for HEIDENHAIN cables and the recommended input circuitry of subsequent electronics. 1) Metal armor 36

37 Noise-free signal transmission Electromagnetic compatibility/ce compliance When properly installed, and when HEIDENHAIN connecting cables and cable assemblies are used, HEIDENHAIN encoders fulfill the requirements for electromagnetic compatibility according to 2004/108/EC with respect to the generic standards for: Noise immunity EN : Specifically: ESD EN Electromagnetic fields EN Burst EN Surge EN Conducted disturbances EN Power frequency magnetic fields EN Pulse magnetic fields EN Interference EN : Specifically: For industrial, scientific and medical equipment (ISM) EN For information technology equipment EN Transmission of measuring signals electrical noise immunity Noise voltages arise mainly through capacitive or inductive transfer. Electrical noise can be introduced into the system over signal lines and input or output terminals. Possible sources of noise include: Strong magnetic fields from transformers, brakes and electric motors Relays, contactors and solenoid valves High-frequency equipment, pulse devices, and stray magnetic fields from switch-mode power supplies AC power lines and supply lines to the above devices Protection against electrical noise The following measures must be taken to ensure disturbance-free operation: Use only original HEIDENHAIN cables. Consider the voltage drop on supply lines. Use connecting elements (such as connectors or terminal boxes) with metal housings. Only the signals and power supply of the connected encoder may be routed through these elements. Applications in which additional signals are sent through the connecting element require specific measures regarding electrical safety and EMC. Connect the housings of the encoder, connecting elements and subsequent electronics through the shield of the cable. Ensure that the shield has complete contact over the entire surface (360 ). For encoders with more than one electrical connection, refer to the documentation for the respective product. For cables with multiple shields, the inner shields must be routed separately from the outer shield. Connect the inner shield to 0 V of the subsequent electronics. Do not connect the inner shields with the outer shield, neither in the encoder nor in the cable. Connect the shield to protective ground as per the mounting instructions. Prevent contact of the shield (e.g. connector housing) with other metal surfaces. Pay attention to this when installing cables. Do not install signal cables in the direct vicinity of interference sources (inductive consumers such as contactors, motors, frequency inverters, solenoids, etc.). Sufficient decoupling from interference-signal-conducting cables can usually be achieved by an air clearance of 100 mm or, when cables are in metal ducts, by a grounded partition. A minimum spacing of 200 mm to inductors in switch-mode power supplies is required. If compensating currents are to be expected within the overall system, a separate equipotential bonding conductor must be provided. The shield does not have the function of an equipotential bonding conductor. Only provide power from PELV systems (EN 50178) to position encoders. Provide high-frequency grounding with low impedance (EN Chap. EMC). For encoders with 11 µapp interface: For extension cables, use only HEIDENHAIN cable ID Overall length: max. 30 m. Minimum distance from sources of interference 37

38 HEIDENHAIN measuring equipment The PWT is a simple adjusting aid for HEIDENHAIN incremental encoders. In a small LCD window the signals are shown as bar charts with reference to their tolerance limits. PWT 10 PWT 17 PWT 18 Encoder input» 11 µa PP «TTL» 1 V PP Functions Measurement of signal amplitude Wave-form tolerance Amplitude and position of the reference mark signal Power supply Dimensions Via power supply unit (included) 114 mm x 64 mm x 29 mm PWM 20 Together with the ATS adjusting and testing software, the PWM 20 phase angle measuring unit serves for diagnosis and adjustment of HEIDENHAIN encoders. Encoder input PWM 20 EnDat 2.1 or EnDat 2.2 (absolute value with/without incremental signals) DRIVE-CLiQ Fanuc Serial Interface Mitsubishi High Speed Serial Interface SSI VPP/TTL/11 µa PP Interface USB 2.0 Power supply Dimensions 100 to 240 V AC or 24 V DC 258 mm x 154 mm x 55 mm ATS Languages Functions System requirements Choice between English or German Position display Connection dialog Diagnostics Mounting wizard for EBI/ECI/EQI, LIP 200, LIC 4000 and others Additional functions (if supported by the encoder) Memory contents PC (dual-core processor; > 2 GHz); RAM > 1 GB; Windows operating systems XP, Vista, 7 (32-bit/64-bit); 100 MB free space on hard disk 38

39 Accessories EIB 1500 The EIB 1500 external interface box is an interpolation and digitizing unit for digital calculation of the positions of two scanning heads on rotational incremental HEIDENHAIN encoders. Absolute position values are available at the output once the reference marks are traversed. The high interpolation (with some encoders up to fold) also enables their use in speed control loops. Specifications EIB 1512 EIB 1592 F EIB 1592 M Input Incremental signals» 1 V PP Output EnDat 2.2 Fanuc Serial Interface Mitsubishi High Speed Serial Interface Ordering designation EnDat 22 Fanuc 02 Mit02-4 Subdivision fold (depending on the encoder) Power supply 3.6 to 14 V DC DRIVE-CLiQ is a registered trademark of the SIEMENS Corporation. Windows is a registered trademark of the Microsoft Corporation. 39